Harley Davidson 2005 touring models. Service repair manual — page 64
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Table 8-7. FLHTP Wire Harness Connectors (Continued)
No.
Description
Type
Location
[131]
Neutral Switch
Post Terminals
Transmission Top Cover
[132]
Cigarette Lighter
Spade Terminals
Inner Fairing
[135]
EFI System Relay
Relay Connector
Fuse Block (Under Right Side Cover)
[139]
Oil Pressure Sender
4-Place Packard
Front Right Crankcase
[141]
Fuel Level Sender/Fuel Pump
3-Place Mini-Deutsch
Top of Canopy (Under Console)
[156]
Main to Interconnect Harness
6-Place Deutsch
Inner Fairing - Right Fairing Support Brace
[160]
B+
1-Place Packard
Upper Frame Cross Member (Under Seat)
[166]
ABS Module
25-Place Amp
Under Right Side Saddlebag
[167]
Front Wheel Speed Sensor
2-Place Tyco
Inner Fairing - Below Upper Fork Bracket (Left Side)
[168]
Rear Wheel Speed Sensor
2-Place Tyco
Under Right Side Cover
[169]
ABS Diagnostics
4-Place Mini-Deutsch
Under Right Side Cover
[176]
Main to Interconnect Harness
6-Place Deutsch
Inner Fairing - Front of Right Fairing Bracket
[67]
p0129x8x
[22]
[24]
[31]
[73]
[20]
[177]
[167]
[32]
Figure 8-48. Headlamp Nacelle (FLHP)
Table 8-8. FLHP Wire Harness Connectors
No.
Description
Type
Location
[4]
Accessory
4-Place Deutsch
Upper Frame Cross Member (Under Seat)
[5]
Maxi-Fuse
2-Place Packard
Under Left Side Cover
[7]
Rear Fender Lights Harness
8-Place Multilock
Top of Rear Fender (Under Seat)
[8]
EFI Harness
12-Place Deutsch (Gray)
Under Right Side Cover
Continued ...
2005 FLT Police: Electrical
8-31
HOME
Table 8-8. FLHP Wire Harness Connectors (Continued)
No.
Description
Type
Location
[18]
Left Rear Turn Signal
2-Place Multilock
Circuit Board Under Tail Lamp Assembly
[19]
Right Rear Turn Signal
2-Place Multilock
Circuit Board Under Tail Lamp Assembly
[20]
Tachometer Assembly
6-Place Deutsch
Inside Headlamp Nacelle
[21]
Indicator Lamps
8-Place Mini-Deutsch
Under Console
[22]
Right Handlebar Controls
12-Place Deutsch
Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Right Side)
[24]
Left Handlebar Controls- Air Horn Option
12-Place Deutsch (Gray)
Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Left Side)
[30]
Turn Signal Module
12-Place Deutsch
Cavity at Rear of Battery Box (Under Seat)
[31]
Front Turn Signal/Pursuit Lamps
6-Place Multilock
Inside Headlamp Nacelle - Fork Stem Nut Lock Plate (Left Side)
[32]
Front Fender Tip Lamp (DOM)
2-Place Multilock (Black)
Inside Headlamp Nacelle
[33]
Ignition/Light Key Switch
3-Place Packard
Under Console
[38]
Headlamp
Headlamp Connector
Inside Headlamp Nacelle
[39]
Speedometer
12-Place Packard
Back of Speedometer (Under Console)
[45]
Rear Fender Tip Lamp (DOM)
3-Place Multilock
Circuit Board Under Tail Lamp Assembly
[46]
Stator
2-Place Packard
Bottom of Voltage Regulator
[57]
Siren/PA Speaker
2-Place Deutsch
Top Rail of Engine Guard (Right Side)
[59]
Rear Pole Lamp
2-Place Deutsch
Under Luggage Rack (Left Side)
[64]
Fuse Block
Packard
Under Left Side Cover
[65]
Vehicle Speed Sensor
3-Place Deutsch
Under Right Side Cover (Behind Electrical Bracket)
[67]
Accessory Switch
4-Place Amp
Inside Headlamp Nacelle
[69]
Pursuit Flasher
Relay Connector
Under Left Side Cover
[72]
Siren Amplifier
18-Place Packard
Top Rail of Saddlebag Guard (Left Side)
[73]
Pursuit Lamps
2-Place Multilock (White)
Inside Headlamp Nacelle
[77]
Voltage Regulator
1-Place Deutsch
Right Lower Frame Tube (Below Transmission Bracket)
[78]
Electronic Control Module (ECM)
36-Place Packard
Under Right Side Cover
[79]
Crankshaft Position (CKP) Sensor
2-Place Mini-Deutsch
Bottom of Voltage Regulator
[80]
Manifold Absolute Pressure (MAP) Sensor
3-Place Packard
Top of Intake Manifold/Induction Module
[83]
Ignition Coil
4-Place Packard
Below Fuel Tank (Left Side)
[84]
Front Injector
2-Place Packard
Below Fuel Tank (Left Side)
[85]
Rear Injector
2-Place Packard
Below Fuel Tank (Left Side)
[87]
Idle Air Control (IAC)
4-Place Packard
Below Fuel Tank (Right Side)
[88]
Throttle Position Sensor (TP Sensor)
3-Place Packard
Below Fuel Tank (Right Side)
[89]
Intake Air Temperature Sensor (IAT Sensor)
2-Place Packard
Below Fuel Tank (Right Side)
[90]
Engine Temperature Sensor (ET Sensor)
2-Place Packard
Back of Front Cylinder (Left Side)
[91]
Data Link
4-Place Deutsch
Under Right Side Cover
[93]
Tail Lamp
4-Place Multilock
Circuit Board Under Tail Lamp Assembly
[94]
Rear Fender Lights Harness to Circuit Board
6-Place Multilock
Circuit Board Under Tail Lamp Assembly
[108]
Tachometer
12-Place Packard (Gray)
Back of Tachometer
[117]
Fuel Gauge
4-Place Multilock
Below Fuel Tank (Left Side)
[119]
EFI Fuses
Fuse Terminals
Fuse Block (Under Right Side Cover)
[120]
Oil Pressure Switch
Post Terminal
Front Right Crankcase
[121]
Rear Brake Light Switch
Spade Terminals
Beneath Transmission
[122]
Horn
Spade Terminals
Between Cylinders (Left Side)
[123]
Starter Relay
Relay Connector
Fuse Block (Under Left Side Cover)
[124]
Brake Light Relay
Relay Connector
Fuse Block (Under Left Side Cover)
[126]
Ignition Keyswitch Relay
Relay Connector
Rear of Battery Box (Under Seat) - Left Side
[128]
Starter Solenoid
Spade Terminals
Top of Starter
[129]
Harness Grounds
Ring Terminals
Upper Frame Cross Member (Under Seat)
Continued ...
8-32
2005 FLT Police: Electrical
HOME
Table 8-8. FLHP Wire Harness Connectors (Continued)
No.
Description
Type
Location
[131]
Neutral Switch
Post Terminals
Top of Transmission
[135]
EFI System Relay
Relay Connector
Fuse Block (Under Right Side Cover)
[141]
Fuel Level Sender/Fuel Pump
3-Place Mini-Deutsch
Top of Canopy (Under Console)
[160]
B+
1-Place Packard
Upper Frame Cross Member (Under Seat)
[166]
ABS Module
25-Place Amp
Under Right Side Saddlebag
[167]
Front Wheel Speed Sensor
2-Place Tyco
Inside Headlamp Nacelle (Left Side)
[168]
Rear Wheel Speed Sensor
2-Place Tyco
Under Right Side Cover
[169]
ABS Diagnostics
4-Place Mini-Deutsch
Under Right Side Cover
[176]
Main to Main Harness
4-Place Deutsch
Under Left Side Cover (Beneath Harness)
[177]
Main to Main Harness
2-Place Deutsch
Inside Headlamp Nacelle (Left Side)
2005 FLT Police: Electrical
8-33
HOME
WIRING DIAGRAMS
8.1
SUBJECT
PAGE NO.
FLHTP
Main Harness
8-37
Interconnect Harness
8-39
Electronic Fuel Injection (EFI) Harness
8-41
Ignition Switch
8-43
Tail Lamp, Pursuit Lamps, Directional Lamps and Fender Tip Lamps
8-43
Starting and Charging
8-45
Handlebar Controls, Speedometer, Tachometer and Indicator Lamps
8-47
Siren Amplifier and Strobe Harness
8-49
Anti-Lock Brake System
8-51
Optional Strobe System
8-63
FLHP, FLHPE
Siren Amplifier and Strobe Harness
8-49
Main Harness
8-53
Electronic Fuel Injection (EFI) Harness
8-55
Starting and Charging
8-57
Handlebar Controls, Indicator Lamps, Tail Lamp, Pursuit Lamps,
Directional Lamps, Accessory/Spot Switch, Speedometer and Tachometer
8-59
Anti-Lock Brake System
8-61
Optional Strobe System
8-63
NOTE
Harness Part No.’s may be included on some wiring diagrams. Use these numbers for
reference only. ALWAYS REFER TO THE 2005 FLT POLICE MODELS PARTS CATALOG
(Part No. 99545-05) WHEN ORDERING WIRING HARNESSES.
2005 FLT Police: Electrical
8-35
HOME
SPECIFICATIONS
A.1
FUSES
System Fuse Block (Under Left Side Cover)
8
7
FLHP/E
Rating
Circuit
Color
(Amperes)
9
13
10
System Fuses
5
Maxi-Fuse
40
Orange
11
Headlamp
15
Blue
14
Ignition
15
Blue
4
Lighting
15
Blue
12
Instruments
15
Blue
Brakes/Pursuit
15
Blue
f2305x8x
3
1
2
Radio Memory
15
Blue
8
7
FLHTP
Radio Power
10
Red
Accessory
15
Blue
9
6
10
Battery
15
Blue
5
11
P & A
15
Blue
13
ABS Motor/Pump Power
20
Red
ABS Solenoid Power
20
Red
14
4
TORQUE VALUES
f2303x8x
2
3
1
Item
ft/in-lbs
Nm
1.
Headlamp
8.
Accessory
2.
Ignition
9.
Battery
ABS module bracket to
3.
Lighting
10.
Brake Light Relay
saddlebag support rail socket
84-108 in-lbs
9.5-12.2 Nm
4.
Instruments
11.
P&A
screws
5.
Brakes/Pursuit
12.
Starter Relay
6.
Radio Memory
13.
ABS Motor/Pump Power
ABS module bracket rubber
60-96 in-lbs
6.8-10.8 Nm
7.
Siren
14.
ABS Solenoid Power
mount screws
Wheel speed sensor button
12-15 in-lbs
1.4-1.7 Nm
Figure A-1. Fuse Locations
head screws
Front wheel speed sensor
28-38 ft-lbs
37.9-51.5 Nm
bracket screws
Brake manifold screws
90-110 in-lbs
10.2-12.4 Nm
Aluminum guide T45 TORX
15-20 ft-lbs
20.3-27.1 Nm
screw
ABS module/brake manifold
17-22 ft-lbs
23.0-29.8 Nm
banjo bolts
Master cylinder/brake caliper
17-22 ft-lbs
23.0-29.8 Nm
banjo bolts
Front brake line bracket to
lower fork bracket T40 TORX
120-180 in-lbs
13.6-20.3 Nm
screw
Rear brake light switch
96-120 in-lbs
10.8-13.6 Nm
Appendix A: Anti-Lock Brake System A-1
HOME
NOTES
A-2
Appendix A: Anti-Lock Brake System
HOME
ABS SYSTEM INTRODUCTION
A.2
GENERAL
9468
The ABS consists of the following components:
● Wheel Speed Sensors/Tone Rings
● ABS Module
● Brake Lines/Brake Manifold/Aluminum Guide
● Tires/Wheels
● ABS Lamp
● ABS Diagnostics Connector [169B]
● Fuses
WHEEL SPEED SENSORS/TONE RINGS
Two hall-effect sensors independently monitor the speed of
Figure A-3. ABS Module
each wheel. One sensor is mounted at the front wheel left
caliper while the other is at the rear wheel right caliper. Each
sensor works in conjunction with a tone ring fastened to the
In order for the ABS to operate correctly, each wheel speed
corresponding brake disc. The sensor counts each tooth on
sensor must be mounted so that it is within 0.020-0.060 inch
the tone ring as it passes and transmits a signal to the con-
(0.508-1.524 mm) from the face of the tone ring. The tone
troller. The controller continuously processes the input to
ring itself also must be in serviceable condition, that is, with
determine when a wheel is about to lock up. See Figure A-2.
teeth that are not damaged, missing or clogged with debris.
If one wheel slows down more than the other during braking,
or deceleration doesn't match a profile stored in memory, the
ABS MODULE
controller instantly responds by sending a command to the
solenoid valve, which halts or releases hydraulic pressure to
The ABS module is located under the right side saddlebag
the brake caliper, then reapplies it once the wheel begins to
and is rubber mounted to a bracket fastened to the saddlebag
speed up again. This cycle, which is the electronic equivalent
support rail. See Figure A-3. The ABS module is a sealed
of manually pumping the brake, is repeated many times per
non-repairable unit that consists of the following components:
second.
● Controller
● Solenoid Valves
● Pump
9469
Controller
The controller monitors and interprets the signals from the
wheel speed sensors and operates the solenoid valves and
pump to independently control the braking force of each
wheel.
Solenoid Valves
Each wheel is provided with two solenoid valves having two
operating positions.
The controller activates each solenoid valve as necessary to
adjust hydraulic pressure to suit braking conditions. When a
Figure A-2. Front Wheel Speed Sensor/Tone Ring
wheel first begins to skid, the normally-open inlet valve closes
Appendix A: Anti-Lock Brake System A-3
HOME
BRAKE LINES
9458
1
Brake lines are routed from the master cylinders to the ABS
module, and then from the ABS module to the brake calipers.
The brake line from the front brake master cylinder is routed
through the brake manifold fastened to the right side of the
steering head, and then continues downward following the
2
right front frame downtube. At the bottom of the downtube,
the brake line is routed rearward along the top of the lower
frame tube. At the bottom of the rear frame downtube, the line
is directed upward through the aluminum guide before con-
necting to the ABS module.
The brake line from the ABS module to the front brake cali-
pers follows this same path passing through both the alumi-
num guide and brake manifold on its way forward. See Figure
A-4 and Figure A-5.
1.
Brake Line to Front Brake Calipers
2. Brake Line from Front Master Cylinder
The brake line from the rear brake master cylinder also fol-
lows the front brake line. As its route begins at the bottom of
Figure A-4. Brake Manifold (Steering Head)
the right front frame downtube next to the rear brake master
cylinder, it follows the top of the lower frame tube and is then
routed upward through the aluminum guide before connecting
9466
1
to the ABS module.
TIRES/WHEELS
ABS motorcycles must always use tires and wheels that are
2
the same as the original equipment. The ABS monitors the
rotational speed of the wheels through individual wheel
speed sensors. Changing to different diameter wheels or dif-
ferent size tires can alter the rotational speed. This can upset
3
the calibration of the ABS and have an adverse effect on its
ability to detect and prevent lockups. Tire inflation pressure
that is significantly low also can have an adverse effect.
1.
Rubber Spacer
2.
Aluminum Guide
3.
T45 TORX Screw
Figure A-5. Rear Frame Downtube
60
40
50
70
30
50
0
80
90
20
60
MPH
RPM x100
to block the movement of brake fluid into the caliper. If
this
100
corrective action is not sufficient to stop the wheel from
lock-
10
70
110
ing up, the normally-closed outlet valve opens and brake fluid
P
120
0
80
pressure is relieved into a low pressure accumulator.
The
reduction in hydraulic pressure then allows the brake pads to
retract.
TI
-D
-D
Pump
During an ABS event, the pump may activate to empty the
ABS Lamp
low pressure accumulator. In fact, this can occur repeatedly
f2306x8x
throughout the duration of the event and may be felt through
Figure A-6. Tachometer (FLHTP)
the brake lever and pedal (see OPERATION in this section).
A-4
Appendix A: Anti-Lock Brake System
HOME
OPERATION
f2314x8x
The controller continuously monitors the wheel speed sen-
sors and watches for any decelerations that are out of the
ordinary. Immediately before a wheel locks up, it experiences
a rapid deceleration, and if left unchecked, the wheel would
stop much sooner than the motorcycle itself. The controller
looks for this rapid deceleration and then instantly reduces
hydraulic pressure to the brake until it sees a corresponding
acceleration, and then it immediately increases the pressure
until it sees the deceleration again.
This is all accomplished very quickly, before the actual speed
of the wheel can change significantly. The result is that the
wheel slows down at the same rate as the motorcycle, with
the brake keeping the wheel very near the point at which it
will start to lock up. This provides for maximum braking power
and efficiency, and in many instances, it also reduces stop-
ping distances in emergency braking situations, particularly
on wet and slippery roads.
ABS Diagnostics
[169B]
When the ABS is in operation during hard stops, a pulsing
sensation or slight vibration may be felt in the brake pedal
Figure A-7. Remove Right Side Cover
and/or hand lever. Sometimes the controller may make a
grinding or clicking noise. This means that the ABS is working
properly. The pulsation or noise originates from the rapid
opening and closing of the solenoid valves and the running of
ABS LAMP
the pump.
The amber ABS lamp in the tachometer face begins to flash
It is important NOT to take your foot off the brake pedal or
at key On to indicate that the system is operational and then
release the brake hand lever when the pulsation or noise
continues to flash until vehicle speed exceeds 6 mph. At
occurs, but maintain firm pressure on the brakes. Never pump
speeds above 6 mph, the lamp will only illuminate when the
the brakes. Pumping the brakes significantly reduces the
ABS senses that the system is malfunctioning. In the diag-
affectiveness of the ABS.
nostic mode, the lamp also will illuminate to indicate the pres-
ence of diagnostic trouble codes (DTC’s). See Figure A-6.
ABS DIAGNOSTICS CONNECTOR
The ABS diagnostics connector [169B], 4-place Mini-Deutsch
socket housing, is located under the right side cover. See Fig-
ure A-7.
When terminals 3 and 4 are crossed, the lamp will remain illu-
minated (after the initial ON/OFF sequence) if no DTC’s are
present, or it will flash the stored DTC’s.
FUSES
Two 20 amp fuses are provided in the system fuse block
under the left side cover. The fuses protect the solenoid
valves and motor/pump circuitry in the ABS module from
damage. See Figure A-1.
Appendix A: Anti-Lock Brake System A-5
HOME
20 AMP FUSES
ABS SOLENOID POWER
R
TO +BATT (TERMINAL B OF MAXI-FUSE)
ABS MOTOR/PUMP POWER
FUSE BLOCK [64]
FLHP/E FLHTP
FLHP/E Fuse Block
FLHTP Fuse Block
Wire
Wire
Fuse
Cavity
Color
20A
10A
20A
10A
Fuse
Cavity
Color
BRAKE
BRAKE
4H
R/V
RELAY
15A
20A
20A
RELAY
15A
15A
3H
R/V
Solenoid
START
Solenoid
ABS MODULE
4G
R
3G
R
RELAY
15A
15A
15A
15A
15A
15A
3B
R/V
4H
R/V
[166A] [166B]
Motor
Motor
3A
R
15A
15A
15A
15A
15A
15A
15A
15A
4G
R
8
R/V
[169B]
CAUTION
9
R/V
ABS
Never place either end of jumper wire on
TO BATTERY FUSE
terminals
1 or
2 of ABS diagnostics
DIAGNOSTICS
1
connector [169B]. Any such contact can
result in permanent damage to the ABS
10
LGN/BN
2
module.
13
BN/O
3
[167B] [167A]
FRONT WHEEL
4
SPEED SENSOR
12
BK/BE
1
1
BK
3
BK/V
W
2
2
[168B] [168A]
Wheel Speed Sensors
Cavity
Function
Color
2
BE/BN
REAR WHEEL
1
Power
Black
1
1
BK
SPEED SENSOR
2
Ground
White
18
BE/V
4
2
2
W
3
TACHOMETER
ABS LAMP
16
O/V
2
1
1
O/BN
4
R/BE
1
2
2
[108B]
8
21
O/BN
3
3
[108A]
8
[176A] [176B]
4
4
5
5
24
BK
1
1
6
6
25
BK
2
2
[176B] [176A]
[177A] [177B]
BK
FLHTP ONLY
FLHP/E ONLY
R/BE
2
FLHTP ONLY
TO BRAKE LIGHT
1
3
SWITCH
1
2
3
4
5
6
7
8
9
10
11
12
[1A]
[1B]
1
2
3
4
5
6
7
8
9
10
11
12
ABS MODULE PINOUT:
8
+BATTERY-SOLENOID POWER
ABS MODULE CONNECTOR [166A]
9
+BATTERY-MOTOR POWER
O/V
TO BRAKES/PURSUIT
10
DIAGNOSTICS
FUSE
13
CODE FLASH PIN
12
+FRONT WHEEL SENSOR
3
-FRONT WHEEL SENSOR
2
+REAR WHEEL SENSOR
ABS MODULE CONNECTOR [166B]
18
-REAR WHEEL SENSOR
16
IGNITION
4
BRAKE SWITCH INPUT
21
ABS WARNING LAMP
24
GROUND
25
GROUND
f2335x8x
Figure A-8. ABS Circuit
A-6
Appendix A: Anti-Lock Brake System
HOME
DIAGNOSTIC INTRODUCTION
A.3
a. If a numbered circle appears adjacent to a box in the
RESOLVING PROBLEMS
flow chart, then more information is offered in the
Diagnostic Notes. The diagnostic notes contain
To resolve system problems, four basic steps are involved. In
supplemental information, descriptions of various
order of occurrence, they are:
diagnostic tools or references to other parts of the
1.
Retrieve diagnostic trouble codes (DTC’s) using the ABS
manual.
self diagnostics. To prevent the possibility of damage to
b. In order to perform most diagnostic routines, the
the ABS module, fashion the DIAGNOSTICS CONNEC-
HARNESS CONNECTOR TEST KIT (Part No. HD-
TOR ADAPTER described in Section A.4 SPECIAL
41404A) and a DVOM are required.
TOOLS. If using a jumper wire to cross terminals 3 and 4
c. When working through a flow chart, refer to the
of ABS diagnostics connector [169B], exercise caution to
associated Circuit Diagram and the Wire Harness
avoid any contact with terminals 1 or 2.
Connector Table. The wire harness connector table
identifies the number, description, type and general
CAUTION
location of each connector in the circuit. To perform
the circuit checks with any degree of efficiency, a
Never place either end of a jumper wire on terminals 1 or
familiarity with the various wire harness connectors
2 of ABS diagnostics connector [169B]. Any such con-
is necessary.
tact can result in permanent damage to the ABS module.
3.
Correct problems through the replacement of faulty com-
2. Diagnose system problems using the special tool and the
ponents. See Section A.18 SERVICE PROCEDURES for
diagnostic flow charts.
details.
NOTE
4.
Validate the work after repairs are performed. This
involves clearing all DTC’s and test riding the motorcycle
For a systematic approach, always begin with the flow charts
to confirm proper operation without setting any codes. To
in Section A.6 INITIAL/FINAL DIAGNOSTIC CHECK. Read
clear DTC’s, see Section A.5 ABS SELF DIAGNOSTICS.
the general information and then work your way through the
flow chart box by box.
Table A-1. Wire Harness Connectors in Figure A-8.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
[1]
Main to Interconnect Harness
FLHTP
12-place Deutsch
Inner Fairing (Right Fairing Bracket)
ABS Solenoid Power Fuse
All
20 Amp (Red)
Fuse Block (Under Left Side Cover)
[64]
ABS Motor/Pump Power Fuse
All
20 Amp (Red)
Fuse Block (Under Left Side Cover)
Brakes/Pursuit Fuse
All
15 Amp (Blue)
Fuse Block (Under Left Side Cover)
FLHP/E
12-place Packard
Back of Tachometer
[108]
Tachometer
FLHTP
12-place Packard
Inner Fairing (Back of Tachometer)
[166]
ABS Module
All
25-place Amp
Under Right Side Saddlebag
FLHP/E
2-place Tyco
Headlamp Nacelle (Left Side)
[167]
Front Wheel Speed Sensor
FLHTP
2-place Tyco
Inner Fairing (Left Side)
[168]
Rear Wheel Speed Sensor
All
2-place Tyco
Under Right Side Cover
[169]
ABS Diagnostics
All
4-place Mini-Deutsch
Under Right Side Cover
Main to Interconnect Harness
FLHTP
6-place Deutsch
Inner Fairing (Right Side)
[176]
Main to Main Harness
FLHP/E
4-place Deutsch
Under Left Side Cover
[177]
Main to Main Harness
FLHP/E
2-place Deutsch
Headlamp Nacelle (Left Side)
Appendix A: Anti-Lock Brake System A-7
HOME
SPECIAL TOOLS
A.4
DIAGNOSTICS CONNECTOR
ADAPTER
To safely retrieve diagnostic trouble codes (DTC’s) using the
ABS self diagnostics, it is necessary to fashion a diagnostic
tool from common components.
1. Obtain the following parts from stock.
f2336x8x
Table A-2. Diagnostics Connector Adapter
Figure A-9. Diagnostics Connector Adapter
PART NO.
DESCRIPTION
QUAN.
74104-98BK
4-Place Mini-Deutsch Pin Housing
1
74144-98
Secondary Locking Wedge
1
74192-98
Pin Terminal, 18 awg
2
2. Obtain 18 gauge wire approximately 6 inches (152.4
mm) in length.
3. After stripping 1/8 inch (3.2 mm) of insulation, crimp pin
terminal onto each end of wire.
4. Remove secondary locking wedge from pin housing.
5. Install wire seal into back of pin housing, if removed.
6. Push pin through wire seal into cavity 3 of pin housing.
Push second pin through wire seal into cavity 4.
7. Gently tug on wires to verify that pins will not back out of
cavities.
8. Install secondary locking wedge into pin housing. See
Figure A-9.
A-8
Appendix A: Anti-Lock Brake System
HOME
ABS SELF DIAGNOSTICS
A.5
REPORTING DTC’s
f2314x8x
1. Remove right side saddlebag and side cover. For best
results, move saddlebag forward slightly before lifting.
2.
Locate ABS diagnostics connector [169B], 4-place Mini-
Deutsch socket housing. See Figure A-10.
3.
Connect Diagnostics Connector Adapter to ABS
diagnostics connector.
NOTE
If the Diagnostics Connector Adapter is not available, obtain
the HARNESS CONNECTOR TEST KIT (Part No. HD-
41404A). Using two brown pin probes and patch cord, place
jumper wire on terminals
3 and
4 of ABS diagnostics
connector.
CAUTION
Never place either end of jumper wire on terminals 1 or 2
of ABS diagnostics connector [169B]. Any such contact
ABS Diagnostics
can result in permanent damage to the ABS module.
[169B]
4.
Turn the Ignition/light key switch to ON while watching
Figure A-10. Remove Right Side Cover
the amber ABS lamp in the tachometer face. See Figure
A-11.
a. The lamp will illuminate momentarily and then go
OUT.
b. If diagnostic trouble codes (DTC’s) do not exist, the
60
40
lamp will then come back ON and remain illuminated
50
70
30
50
0
80
until the diagnostic sequence is exited using one
of
90
20
60
the methods described under step 6. See B of
Fig-
MPH
RPM x100
100
ure A-12.
10
70
110
c. On the other hand, if DTC’s are present, then
the
P
120
0
80
ABS lamp will begin to flash after the initial ON/OFF
sequence. See A of Figure A-12.
TI
For each code transmitted, there will be one or more
-D
-D
long flashes, about 3 seconds in duration, followed
by one or more short flashes, about 0.5 seconds
long.
Write down the number of long flashes (main code)
ABS Lamp
f2306x8x
and short flashes (secondary code) on a piece of
paper, each number separated by a dash.
Figure A-11. Tachometer (FLHTP)
For example, one long flash followed by two short
flashes is written as “1-2.” Looking at the table on the
6.
To exit the diagnostic sequence without clearing codes,
next page, we see that code 1-2 indicates that the
either turn the Ignition/light key switch to OFF or remove
front wheel speed sensor “fails intermittently and/or
the Diagnostics Connector Adapter (or jumper wire) from
the speed sensor signal is out of specification.”
the ABS diagnostics connector. The diagnostic sequence
also will be aborted whenever the speed of the vehicle
5.
Write down the remaining codes in the same manner.
exceeds 6 mph.
Once all codes are flashed, the sequence is repeated.
NOTE
Observe the sequence a second time to verify that all
The system stores only the first error code detected on each
codes were written and that they were written correctly.
ignition cycle. If more than one DTC is stored, then they are
reported in numerical (not chronological) order.
Appendix A: Anti-Lock Brake System A-9
HOME
f2304x8x
1st Code
2nd Code
1-2
3-1
T6
A
Trouble Codes Present
T6
T1
T3
T3
ON
OFF
T2
T5
T2
Key On
T4
Sequence Restarted
T7
B
T1
Lamp Remains ON: No Trouble Codes
ON
T1: Initial Lamp On Time (2.0 sec.)
OFF
T2: Main Code Interval- Time Off (3.0 sec.)
T2
Key On
T3: Main Code Lamp On Time (1.5 sec.)
T4: Main Code Lamp Off Time (0.5 sec.)
T5: Sub Code Interval- Time Off (0.5 sec.)
T6: Sub Code Lamp On Time (0.5 sec.)
T7: Sub Code Lamp Off Time (0.5 sec.)
Figure A-12. ABS Lamp Operation
Table A-3. ABS Diagnostic Trouble Codes (DTC’s)
DTC
DESCRIPTION
FAULT CONDITION
SOLUTION
1-1
Front Wheel Speed Sensor
Failed Short/Open
Failed Intermittent/
A.9 FRONT WHEEL SPEED SENSOR: DTC 1-1, 1-2
1-2
Front Wheel Speed Sensor
Signal Out of Specification
1-3
Rear Wheel Speed Sensor
Failed Short/Open
Failed Intermittent/
A.10 REAR WHEEL SPEED SENSOR: DTC 1-3, 1-4
1-4
Rear Wheel Speed Sensor
Signal Out of Specification
2-1
Front Tone Ring
Deformation/Damage
A.11 FRONT/REAR TONE RING: DTC 2-1, 2-3
2-3
Rear Tone Ring
Deformation/Damage
3-1
Rear-In Solenoid
Open/Short
3-2
Rear-Out Solenoid
Open/Short
A.12 SOLENOID: DTC 3-1, 3-2, 3-3, 3-4
3-3
Front-In Solenoid
Open/Short
3-4
Front-Out Solenoid
Open/Short
4-1
Front Caliper
Wheel Locks
A.13 FRONT/REAR CALIPER: DTC 4-1, 4-3
4-3
Rear Caliper
Wheel Locks
5-1
Motor (Pump)
Motor Locks
5-2
Motor (Pump)
Motor Failed OFF
A.14 MOTOR (PUMP)/RELAY: DTC 5-1, 5-2, 5-3, 5-4
5-3
Motor (Pump)
Motor Failed ON
5-4
Fail Safe Relay
Failed ON/Failed OFF/Sticks
6-1
Battery Voltage
Below Normal
A.15 BATTERY VOLTAGE: DTC 6-1, 6-2
6-2
Battery Voltage
Above Normal
7-1
Tires
Tire Size Difference
A.16 TIRES: DTC 7-1
8-1
ABS Module
Internal Error
A.17 ABS MODULE: DTC 8-1
A-10
Appendix A: Anti-Lock Brake System
HOME
5. Apply either brake and hold until the ABS lamp goes out
CLEARING DTC’s
again.
To clear all diagnostic codes stored in memory, proceed as
6. Release the brake, and after approximately 4 seconds,
follows:
the ABS lamp flashes to confirm that all DTC’s are
cleared.
1. Install the Diagnostics Connector Adapter or place
jumper wire across terminals 3 and 4 of ABS diagnostics
7. Remove the Diagnostics Connector Adapter (or jumper
connector [169B]. Remember, exercise caution to avoid
wire).
contact with terminals 1 or 2 if a jumper wire is used. Any
such contact can result in permanent damage to the
ABS module.
2. Apply either brake (hand or foot) and hold.
3. Turn the Ignition/light key switch to ON. The ABS lamp
will illuminate and then go off.
4.
Release the brake and wait until the ABS lamp comes
back on.
Appendix A: Anti-Lock Brake System A-11
HOME
INITIAL/FINAL DIAGNOSTIC CHECK
A.6
GENERAL
DIAGNOSTICS
Initial Diagnostic Check
Diagnostic Notes
Whenever DTC’s are reported, always perform the diagnostic
The reference numbers below correlate with the circled num-
check before proceeding to the appropriate flow chart. This
bers on the Test A.6 flow charts.
check will confirm that the problem is not the result of an ABS
1.
Sometimes errant code may be set by wheel slip or
malfunction, whether temporary or permanent.
riding on rough road.
Final Diagnostic Check
After using the appropriate flow chart to diagnose the prob-
lem and then finishing the repair, perform the diagnostic
check again to confirm that the problem has been corrected.
A-12
Appendix A: Anti-Lock Brake System
HOME
Test A.6 (Part 1 of 1)
INITIAL/FINAL DIAGNOSTIC CHECK
Clear all DTC’s. Turn the igni-
tion switch to OFF and then
back to ON. Report DTC’s.
Are DTC’s still present?
YES
NO
Go to the appropriate
Ride the motorcycle
flow chart.
above 6 mph. Does the
ABS lamp illuminate?
YES
NO
Go to the appropriate flow
System OK.
1
chart and wiggle harness
while performing test to
identify intermittents.
Appendix A: Anti-Lock Brake System A-13
HOME
NO ABS LAMP AT KEY ON
A.7
GENERAL
See Figure A-13. Under normal operation, the ABS lamp will
flash at key on and become extinguished at speeds greater
60
40
50
70
30
50
than 6 mph (9.7 kph). If the lamp fails to illuminate, ABS
0
80
power may not be present or the lamp circuit may be faulty.
90
20
60
MPH
RPM x100
100
10
70
110
P
DIAGNOSTICS
120
0
80
TI
-D
-D
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test A.7 flow chart.
ABS Lamp
1. To perform “wow” test, press and hold odometer reset
f2306x8x
switch and then turn ignition switch ON. Release reset
switch. Background lighting should illuminate, speedom-
Figure A-13. Tachometer (FLHTP)
eter and tachometer needles should sweep their full
range of motion, and the check engine, low fuel level,
battery, security, cruise, pursuit and ABS lamps should
illuminate in the speedometer and tachometer faces.
2. Enable ABS lamp on replacement tachometer using
DIGITAL TECHNICIAN (Part No. HD-44750).
3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404A), dark blue pin probes and patch cord.
1WARNING
HD46601
Use only gray pin probes from HARNESS CONNECTOR
TEST KIT (Part No. HD-41404A) on small terminals (1-7,
Figure A-14. Instrument Harness Adapters
10-23) of ABS Module connector [166B], and dark blue
(Part No. HD-46601)
pin probes on large terminals (8-9, 24-25). Use of the
wrong probes can damage terminals causing insufficient
or excessive current to be passed to solenoid valves
and/or pump, a condition which could cause the ABS to
malfunction, possibly resulting in death or serioius
injury.
4. Connect BREAKOUT BOX (Part No. HD-42682) and
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601) between wire harness and tachometer. See Fig-
ure A-14 and Figure A-15.
5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404A), gray pin probes and patch cord.
f2001x8x
f1998x9x
Figure A-15. Breakout Box (Part No. HD-42682)
A-14
Appendix A: Anti-Lock Brake System
HOME
ABS MODULE
[166A] [166B]
20 AMP FUSES
ABS SOLENOID POWER
8
R/V
R TO +BATT (TERMINAL B OF MAXI-FUSE)
9
R/V
ABS MOTOR/PUMP POWER
FUSE BLOCK [64]
FLHP/E FLHTP
FLHP/E Fuse Block
FLHTP Fuse Block
Wire
Wire
Fuse
Cavity
Color
20A
10A
20A
10A
Fuse
Cavity
Color
BRAKE
BRAKE
4H
R/V
RELAY
15A
20A
20A
RELAY
15A
15A
3H
R/V
Solenoid
START
Solenoid
4G
R
3G
R
RELAY
15A
15A
15A
15A
15A
15A
3B
R/V
4H
R/V
Motor
Motor
3A
R
15A
15A
15A
15A
15A
15A
15A
15A
4G
R
4
TACHOMETER
3
ABS LAMP
16
O/V
2
1
1
O/BN
4
R/BE
1
2
2
[108B]
8
21
O/BN
3
3
[108A]
8
[176A] [176B]
4
4
5
5
24
BK
1
1
6
6
25
BK
2
2
[176B] [176A]
[177A] [177B]
BK
FLHTP ONLY
FLHP/E ONLY
R/BE
2
FLHTP ONLY
TO BRAKE LIGHT
1
3
SWITCH
1
2
3
4
5
6
7
8
9
10
11
12
[1A]
[1B]
ABS MODULE PINOUT:
1
2
3
4
5
6
7
8
9
10
11
12
8
+BATTERY-SOLENOID POWER
ABS MODULE CONNECTOR [166A]
9
+BATTERY-MOTOR POWER
O/V
TO BRAKES/PURSUIT
16
IGNITION
FUSE
4
BRAKE SWITCH INPUT
21
ABS WARNING LAMP
24
GROUND
25
GROUND
ABS MODULE CONNECTOR [166B]
f2335b8x
Figure A-16. ABS Lamp Circuit
Table A-4. Wire Harness Connectors in Figure A-16.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
[1]
Main to Interconnect Harness
FLHTP
12-place Deutsch
Inner Fairing (Right Fairing Bracket)
ABS Solenoid Power Fuse
All
20 Amp (Red)
Fuse Block (Under Left Side Cover)
[64]
ABS Motor/Pump Power Fuse
All
20 Amp (Red)
Fuse Block (Under Left Side Cover)
FLHP/E
12-place Packard
Back of Tachometer
[108]
Tachometer
FLHTP
12-place Packard
Inner Fairing (Back of Tachometer)
[166]
ABS Module
All
25-place Amp
Under Right Side Saddlebag
Main to Interconnect Harness
FLHTP
6-place Deutsch
Inner Fairing (Right Side)
[176]
Main to Main Harness
FLHP/E
4-place Deutsch
Under Left Side Cover
[177]
Main to Main Harness
FLHP/E
2-place Deutsch
Headlamp Nacelle (Left Side)
Appendix A: Anti-Lock Brake System A-15
HOME
Test A.7 (Part 1 of 1)
NO ABS LAMP AT KEY ON
Perform “wow” test
1
to verify gauge
functionality. Did gauge
function and ABS lamp
illuminate?
YES
NO
NO
Gauge does not function
Gauge functions properly
and ABS lamp does not
but ABS lamp does not
illuminate.
illuminate.
Check for voltage
3
between sockets 9 (+)
and 25 (-) of connector
[166B]. Is battery
See Tachometer
Was tachometer
voltage present?
Troubleshooting in the
just replaced?
2005 Touring Electri-
cal Diagnostic Manual
(Part No. 99497-05).
YES
NO
YES
NO
Check for resistance to ground
Check for resistance
Enable ABS lamp
Replace
2
on replacement
tachometer.
on socket 24 of connector
to ground on socket 25
[166B]. Resistance less than
of connector [166B].
tachometer using
Digital Technician
6772
0.5 ohms?
Resistance less than
(HD-44750).
0.5 ohms?
2432
YES
NO
YES
NO
Check for resistance between
Locate and repair high
socket 8 of connector [166B] and
resistance on BK wire
Check for resistance
Locate and repair high
between socket 9 of
resistance on BK wire
ABS solenoid power fuse.
between socket 24 of
Resistance less than 0.5 ohms?
connector [166B] and
connector [166B] and
between socket 25 of
ABS motor power fuse.
connector [166B] and
ground.
Resistance less than
ground.
2417
0.5 ohms?
2417
YES
NO
Measure resistance on R
Locate and repair high
YES
NO
wire between ABS
resistance on R/V wire
solenoid power fuse and
between socket 8 of
Locate and repair high
Locate and repair high
battery. Resistance less
connector [166B] and
than 0.5 ohms?
ABS solenoid power fuse.
resistance on R wire
resistance on R/V wire
between ABS motor
between socket 9 of
2427
power fuse and battery.
connector [166B] and
ABS motor power fuse.
2422
YES
NO
2427
Measure continuity on
Locate and repair high
4
O/BN wire between
resistance on R wire
socket 21 of connector
between ABS solenoid
5
[166B] and terminal 8
power fuse and battery.
of connector [108B].
2422
Resistance less than 0.5
ohms?
YES
NO
Replace ABS
Locate and repair open
module.
between socket 21 of
connector [166B] and
2430
terminal 8 of connector
[108B].
2438
A-16
Appendix A: Anti-Lock Brake System
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